Battery Pack Maintenance Cover Interlock for Electric Shock Isolation
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Solution Overview
Problem
Battery packs in vehicles are not reliably powered off during maintenance, posing a risk of electric shock to maintenance personnel due to live components, which can lead to irreparable damage.
Innovation Solution
A structure incorporating a low-voltage control circuit, relay, and switch with a plug and socket, allowing for automatic power-off of the main circuit when the maintenance cover is detached, ensuring both electrical and mechanical disconnection to prevent electric shock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the battery pack is fixed inside the car body with a maintenance port, then maintenance personnel can access and repair components directly, but the battery pack cannot be reliably powered off during maintenance, creating electric shock risk
Solution Approach 1:
The patent applies preliminary action by automatically cutting off power to the main circuit before maintenance personnel access the battery pack. The switch mechanism is designed to disconnect the plug upon opening the maintenance cover, ensuring power is cut off in advance before any maintenance operations begin, thereby eliminating electric shock risk while maintaining ease of access
2Productivity
If the maintenance cover is designed for easy detachment, then maintenance operations can be performed quickly, but there is no indication confirming the battery pack is completely powered off
Solution Approach 1:
The patent implements feedback by providing visual indication through different colored light-emitting diodes (LEDs) that confirm the power-off status. When the maintenance cover is opened and the plug is disconnected, the system provides optical feedback to confirm that the main circuit is powered off, ensuring reliability while maintaining quick access for maintenance operations
3Object-affected harmful factors
If a switch mechanism is added to ensure automatic power-off, then electric shock risk is reduced, but the device complexity increases
Solution Approach 1:
The patent applies self-service by designing the switch mechanism to automatically disconnect the plug when the maintenance cover is opened. The system serves itself by using the mechanical action of opening the cover to trigger the power-off sequence, eliminating the need for manual intervention or complex control systems, thereby reducing overall device complexity while ensuring safety
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures safe maintenance by automatically powering off the main circuit upon detachment of the maintenance cover, providing dual protection against electric shock through electrical and mechanical disconnection, enhancing safety for maintenance personnel.
Implementation Method 1
a relay; when the plug and the socket are electrically and mechanically connected, the low-voltage control circuit is powered on, and the relay is closed and energized to activate the main circuit. When the plug and socket are electrically or mechanically disconnected, the low-voltage control circuit is cut off, and the relay is open and de-energized to cut off the main circuit
Data Source
AI summary
This disclosure provides a structure designed to enable maintenance without risk of electric shock and a battery pack, including: a structure body provided with a low-voltage control circuit, a main circuit, and a relay; a maintenance cover installed on the structure body; and a switch connected in series with the low-voltage control circuit. The switch includes a plug and a socket, the plug and the socket are respectively equipped on the structure body and on the maintenance cover. When the plug and the socket are electrically and mechanically connected, the low-voltage control circuit is powered on, and the relay is closed and energized to activate the main circuit. When the plug and socket are electrically or mechanically disconnected, the low-voltage control circuit is cut off, and the relay is open and de-energized to cut off the main circuit.